Instant roux

ABSTRACT

This invention relates to an instant roux comprising co-processed modified starch and flour and fat. In addition, the invention relates to the process for providing such “ready-for-use” compositions and the improved food products prepared from the co-processed compositions.

This application is a Continuation-In-Part (“CIP”) of U.S. Pat. No.6,777,015 issued 17 Aug. 2004, which is a CIP of U.S. Ser. No.09/809,968 filed 16 Mar. 2001, now abandoned.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to a thickener or thickening composition thatincludes a “co-processed” combination of modified starch, flour and fatfor use in foods. In addition, the invention relates to the process forproviding such “ready-for-use” compositions and the improved foodproducts prepared from the co-processed compositions. More particularly,the present invention is directed toward a thickening composition usefulas an instant roux.

2. Background Information

A roux is known in the art as a mixture of equal amounts of flour andfat for use as a thickening agent in a soup or sauce. Traditionally,roux is prepared by melting fat, e.g., butter, in a pan and carefullyadding flour while blending the two components. Cooking the flour in fatcauses the flour granules to break. When liquid is added, the flourgranules absorb the liquid, thickening the sauce. The flour is alsoblended with fat because flour clumps and lumps if mixed in a sauce byitself. In preparing a roux melted butter and flour are typically mixedtogether and cooked until bubbly. The flour needs to be stirredconstantly during this preparation in order to keep it from lumping. Theprocess is labor intensive and requires great skill, but produces a rouxwith excellent thickening properties and a desirable taste andmouthfeel.

Roux comes in varying shades from off-white to the much darker brownshades. There are four names that are generally associated with thesevarying shades—white, blond, brown and dark. The color produced dependson the time and temperature used in cooking the flour. Flour cooked overa low heat for a long period of time will be light in color. Flourcooked over a high heat quickly will be darker, have a stronger flavor,and will not be a strong a thickener as a lighter roux. This thickeningmixture can be browned very deeply for used in food dishes such asétouffée and brown sauce. If not browned, the thickener can be used as abase for béchamel, velouté or white sauce. Still, these thickeners arenot suitable for large-scale commercial production. Also, the productscannot be further processed for use in dried foodstuffs.

The use of starches, both unmodified and modified, in thickening agentspresents long recognized problems, particularly for professionals in thefood service industry. Unmodified starch-containing thickeners must beprecooked before being used to increase the viscosity of cold orprecooked foods. However, the use of a precooked, unmodified starchoften imparts an undesirable stringiness to the texture of the food.While the addition of a modified starch can confer a satisfactorytexture to cold or precooked foods, these foods do not provide thedesirable taste and appearance of foods prepared from thickenerscontaining modified starches that have been precooked with flour. Thisis particularly true of foods such as gravies and soups that rely uponthe traditional taste and opacity conveyed by an industry standardthickener containing cooked flour and/or modified starch.

Further, in the food service industry it is often necessary to maintainfoods at high temperatures over relatively long periods of time. This isparticularly true of thickener-containing foods such as gravies andsoups. However, under these conditions an unmodified starch thickener isoften unable to maintain a desirable viscosity. Moreover, after cookingand cooling foods containing an unmodified starch thickener, there isoften an undesirable separation of fat or absorbed water from apreviously homogeneous mix or emulsion. In addition, undesirable weepingand syneresis may occur, particularly after cold storage or freezing andthawing.

While thickeners employing modified starches do not possess theseprocess tolerance limitations inherent to unmodified starches and/orflours, thickeners prepared from modified starches do not have thedesirable cooked flour taste and appearance of thickeners prepared fromunmodified starches and/or flours. As a result, the use of modifiedstarch thickeners in foods often imparts a “synthetic” appearance as thefoods are more translucent and have a glossy shine compared to foodsprepared from unmodified starch and/or flour thickeners.

Various processes have been proposed for producing an ‘instant’ rouxproduct that forms a roux upon the addition of liquid without theformation of lumps. For example, U.S. Pat. No. 4,568,551 discloses aprocess wherein a mixture of edible fat and starchy material isheat-treated together. This heat treatment can be optionally done eitherin the presence of added water or under elevated pressure. The heatedproduct is cooled to form a solid, which is then grated to a powder foruse as an instant roux. The starchy material is preferably flour,particularly wheat, rice or rye, but can also be granular,non-gelatinized starches. Modification of the starch is not taught. Thefat component is edible fat, particularly high-melting edible fat havinga melting point around 44° C. The fat content utilized is in the rangeof 30 to 60% by weight, and the starchy material generally rangesbetween about 25% and 80% by weight.

U.S. Pat. No. 5,895,676 teaches a process in which particulatefarinaceous material is coated with molten fat in an enclosed coatingzone. The molten fat is sprayed in the form of fine droplets onto theparticles and cooled to form a flowable particulate product or bindingagent. The resultant binding agent is readily dispersible in hot water.The farinaceous material preferably contains at least 50% by weight offlour, particularly wheat flour. Agglomerated starches such as potatostarch, corn starch and wheat starch can be used in combination with theflour. The fat used is an edible, high melting point fat that has amelting point in the range of 40° to 45° C., such as hydrogenated palmoil fat. The resultant binding agent can be added to dried soup mixes,dried gravy mixes, dried sauce mixes and the like.

International Publication No. WO 98/03087 discloses a food thickenerprepared by forming a mixture of starch and fat, and solidifying themixture to form the food thickener. The fat is typically melted prior tomixing with the starch. The fats include any of a wide range of fats andoils, and are preferably selected from those having a steep meltingcurve, i.e., the transition from solid to liquid occurs over a narrowtemperature range, preferably in the range of 35° C. to 50° C. Thestarch or starch-containing material is at least 70% starch and mayinclude protein such as casein. Preferred starch materials are flours,including enzyme-inactivated flour, precooked flour, pregelatinizedflour, dried or heat treated flour and synthetic flour. No modified orgranular starches are taught or suggested by WO 98/03087. The liquidflour/fat mixture is atomized and then cooled to a powder.

European Patent No. 0 384 124 B1 discloses a process for preparingstarch-containing, granular instant products, i.e., products that makepossible a rapid and convenient preparation by boiling or stirring inwater. The starch containing materials are mixed together without waterand extruded. The starch-containing materials are preferably groundcereal products, particularly wheat flour, coarse wheat meal, corn meal,durum wheat flour or durum wheat semolina. The starch-containingmaterials can also include emulsifying agents such as lecithin and mono-and diglycerides, proteins such as whey or other milk proteins,flavorings and/or spices, and colorants. The powder from this extrusioncan be used by itself as a sauce binder or can be mixed with a fatpowder to form an instant roux. Fat powders preferably include thoseprepared by spray drying an emulsion of the fat. Fats exemplifiedincluded soybean oil and palm kernel oil. When mixed with the fatpowder, the starch:fat ratio ranges from 50:50 to 90:10.

Japanese Patent No. 10 337 166 teaches a white roux prepared by mixing40-60 weight % hydrogenated rape seed oil and fat with 40-60 weight %flour.

Still there is a need for an instant roux for use in cookingapplications that provides the flavor, texture and color of atraditionally prepared roux as described above but in an easy-to-use,non-lumping, instant powder form. Further, there is a need for such aninstant, powder-based roux that can be easily rehydrated or addeddirectly to soups, sauces and other similar food products.

There is also a need for an instant roux for use in cooking applicationsthat provides high quality thickened soups, sauces and the like that aresmooth and velvety in texture while providing a home-made flavorcomparable to sauces and soups made from a roux prepared in thetraditional manner.

SUMMARY OF THE INVENTION

The instant roux of the invention can be used in sauces, spreads,toppings, soups, fillings and gravies, including their dehydratedpreparations that are hydrated by the consumer immediately prior to use.Thus, the instant roux of the present can be used as for thickeningsauces and other liquid/semi-liquid foodstuffs upon the addition of ahot liquid, e.g., hot water, fond brun such as brown veal stock, milk,etc. The instant roux of the present invention can be easily dispersedin hot liquid without substantial lump formation, and has desirableorganoleptic properties.

Thus, according to the present invention there is provided a process forproducing a “ready-for-use” or instant roux comprising forming aco-processed mixture of flour and starch, and blending this thickeningmixture with fat to form the instant roux. The co-processed mixture isprepared by blending at least one modified starch, particularly astabilized and cross-linked or thermally inhibited starch, with at leastone flour, particularly wheat flour, and co-processing the blend.Preferably, the co-processed material is present at a level of at least50 weight % with respect to the fat, e.g., at a material:fat ratio ofabout 55:45 to 90:10. The material/fat mixture can be formed withoutadded water.

The fat for use in the invention may comprise any of a wide range offats or oils. In one aspect, the fats are selected from those whichexhibit a steep melting curve, i.e., those fats wherein the transitionfrom solid to liquid states occurs over a relatively narrow temperaturerange, e.g., over a range of 15° C. or less.

The nature of the fat can have a great influence on the characteristicsof the roux powder. The fat used in the present invention is an ediblefat. In one embodiment, the fat is a vegetable fat such as palm oil.Useful fats include both animal and vegetable fats. A useful example ofan animal based fat is stearin. In one embodiment the fat is ahydrogenated vegetable oil. Useful hydrogenated fats include, e.g.,cottonseed oil, soybean oil, rapeseed oil and mixtures thereof. Otheruseful fats include fat blends, such as the Beatreme® powdered vegetableshortenings available from Kerry Ingredients, Inc. These blends caninclude, for instance, a vegetable oil such as an hydrogenated vegetableoil, an emulsifier and/or stabilizer such as sodium caseinate, andnonfat milk solids.

The invention also contemplates an instant roux obtained by the processof the invention, as well as a foodstuff comprising such instant roux.Instant roux containing foodstuffs include dried food bases,particularly those for use in sauces, soups and gravies.

In yet another aspect of the invention there is provided a process forpreparing a roux powder. This process involves forming a mixture of aco-processed thickener and fat to form a roux powder. The fat can bemelted and then mixed with the thickener, preferably until the mixtureis homogenous. This thickener/fat mixture can then be spray dried, witha consistent ratio of flour to fat achieved in the powder. The size ofthe particles can be controlled simply by the size of droplets formedupon atomization.

In an optional embodiment, flour can be added to the instant rouxcomposition. The choice of flour also influences the nature of the rouxpowder significantly. Normally, flours contain at least 10% moisture,typically in the range 12 to 14% moisture. For the present invention, ithas been found that flours with reduced moisture content form a superiorroux powder, e.g., flours with less than 8% moisture. In another aspect,flours with moisture content less than 4% are used.

Optionally, other hydrocolloids such as pregelatinized or cold waterswelling starches and/or modified starches can be added to enhancefunctionality of the roux, such as mouthfeel. Other functional additivesmay also be used, including emulsifiers such as lecithin, flavors suchas butter flavor, colorants and proteins such as whey or casein or itssalts. Other additives for enhancing the opacity of the roux, e.g.,titanium dioxide, can be added.

The resultant roux compositions may advantageously be used as“ready-for-use” or instant roux having superior properties to rouxprepared with flour and fat. The foods prepared from these roux haveimproved appearance, taste, process tolerance, emulsification, cold andhot temperature stability and instant viscosity properties compared toindustry standard roux prepared from a combination of flour and fat.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to an instant roux composition comprising aco-processed combination of modified starch and flour having desirableappearance, taste, process tolerance, emulsification, cold and hottemperature stability and instant viscosity properties and fat. Inaddition, the invention relates to the process for providing such“ready-for-use” compositions and the improved food products preparedfrom the co-processed compositions.

All starches and flours (hereinafter “starch”) derived from any nativesource may be suitable for use as the base starch herein. A nativestarch as used herein, is one as it is found in nature. Also suitable asthe base starch are starches and flours derived from a plant obtained bystandard breeding techniques including crossbreeding, translocation,inversion, transformation or any other method of gene or chromosomeengineering to include variations thereof. In addition, starch or floursderived from a plant grown from artificial mutations and variations ofthe above generic composition which may be produced by known standardmethods of mutation breeding are also suitable for use as the basestarch as defined herein.

Typical sources for the base starches include cereals, tubers, roots,legumes and fruits. The native source can be corn, pea, potato, sweetpotato, banana, barley, wheat, rice, sago, amaranth, tapioca, arrowroot,canna, sorghum, and waxy or high amylose varieties thereof. powder,e.g., flours with less than 8% moisture. In another aspect, flours withmoisture content less than 4% are used.

Optionally, other hydrocolloids such as pregelatinized or cold waterswelling starches and/or modified starches can be added to enhancefunctionality of the roux, such as mouthfeel. Other functional additivesmay also be used, including emulsifiers such as lecithin, flavors suchas butter flavor, colorants and proteins such as whey or casein or itssalts. Other additives for enhancing the opacity of the roux, e.g.,titanium dioxide, can be added.

The resultant roux compositions may advantageously be used as“ready-for-use” or instant roux having superior properties to rouxprepared with flour and fat. The foods prepared from these roux haveimproved appearance, taste, process tolerance, emulsification, cold andhot temperature stability and instant viscosity properties compared toindustry standard roux prepared from a combination of flour and fat.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to an instant roux composition comprising aco-processed combination of modified starch and flour having desirableappearance, taste, process tolerance, emulsification, cold and hottemperature stability and instant viscosity properties and fat. Inaddition, the invention relates to the process for providing such“ready-for-use” compositions and the improved food products preparedfrom the co-processed compositions.

All starches and flours (hereinafter “starch”) derived from any nativesource may be suitable for use as the base starch herein. A nativestarch as used herein, is one as it is found in nature. Also suitable asthe base starch are starches and flours derived from a plant obtained bystandard breeding techniques including crossbreeding, translocation,inversion, transformation or any other method of gene or chromosomeengineering to include variations thereof. In addition, starch or floursderived from a plant grown from artificial mutations and variations ofthe above generic composition which may be produced by known standardmethods of mutation breeding are also suitable for use as the basestarch as defined herein.

Typical sources for the base starches include cereals, tubers, roots,legumes and fruits. The native source can be corn, pea, potato, sweetpotato, banana, barley, wheat, rice, sago, amaranth, tapioca, arrowroot,canna, sorghum, and waxy or high amylose varieties thereof. Sources ofparticularly useful base starches include tapioca, dent corn, waxymaize, potato, sago, and rice. As used herein, the term “waxy” includesa starch or flour containing at least about 95% by weight amylopectin,and the term “high amylose” includes a starch or flour containing atleast about 40% by weight amylose.

The base starch will be subsequently modified unless the base starch isinherently stabilized as described infra, though an inherentlystabilized starch may also be subject to subsequent modification. Basestarches suitable for subsequent modification are also intended toinclude conversion products derived from any of the starches, includingfluidity or thin-boiling starches prepared by oxidation, enzymeconversion, acid hydrolysis, heat and or acid dextrinization, thermaland or sheared products.

The base starch can be modified via a variety of known methods, providedthe modification does not destroy the granular nature of the starch. Thebase starch may be treated by a combination of modifications in anyorder. As used herein, modified starches include, without limitation,crosslinked starches, thermally inhibited starches, stabilized starches,acetylated and organically esterified starches, hydroxyethylated andhydroxypropylated starches, phosphorylated and inorganically esterifiedstarches, cationic, anionic, nonionic, and zwitterionic starches, andsuccinate and substituted succinate derivatives of starch. Suchmodifications and combinations thereof are known and their preparationsare described in the art. For example, see Whistler, R. L., BeMiller, J.N. and Paschall E. F., Chpt. 9, § 3, Starch Chemistry and Technology,2^(nd) Ed., Academic Press, Inc., London, pp. 324-349 (1984) andModified Starches: Properties and Uses, Wurzburg, Editor, CRC Press,Inc., Florida (1986). Further, modification by thermal inhibition, suchas that described in International Publication No. WO 95/04082, is alsosuitable for use herein.

The term “stabilized starch” includes starches wherein the base starchis substituted with one or more monofunctional chemical blocking groups,as well as base starches that inherently demonstrate stabilizedproperties. A base starch that demonstrates inherently stabilizedproperties is also defined to be a modified starch for the purposes ofthis application. Foods containing stabilized starches are characterizedby the ability to substantially retain their texture (e.g., viscosity)and other desirable properties, such as color and clarity, duringfreeze/thaw cycling.

Examples of useful monofunctional substituted stabilized starchesinclude, without limitation, starch esters and ethers, including starchacetates, starch octenyl succinate, starch phosphates, and starchhydroxy alkylates. The preparation and properties of such stabilizedstarches are known in the art and described, for example, in R. L.Whistler, J. N. BeMiller, and E. F. Paschall, Chpt. 9, § 5, pp. 343-349,Starch Chemistry and Technology, 2nd Ed, Academic Press, Inc. London(1984), and R. L. Whistler and J. R. Daniel, Chpt 3, p. 119,Carbohydrates, Food Chemistry, 2^(nd) Ed., edited by O. R. Fenenma,Marcel Dekker, Inc., New York (1985).

Starches that are inherently stabilized (demonstrate stabilizedproperties without monofunctional substitution) include, withoutlimitation, waxy maize starches having at least one recessive sugary-2allele. An example of such a starch includes waxy maize starch derivedfrom a plant having endosperm tissue that is heterozygous, with eitherone or two doses, for the recessive sugary-2 allele, described furtherin U.S. Pat. No. 5,954,883. Another example includes starch derived froma waxy maize plant of a wxsu2 (homozygous) genotype and translocations,inversions, mutants and variants thereof, discussed in U.S. Pat. No.4,428,972.

Particularly useful modified starches are food quality starches in whichthe starch is dually modified by stabilizing and crosslinking thestarch, or by stabilizing and thermally inhibiting the starch. In oneaspect, useful stabilized and crosslinked starches include, for example,hydroxypropylated distarch phosphate, acetylated distarch adipate, andwaxy maize starches having at least one recessive sugary-2 allele thatare subsequently crosslinked or thermally inhibited. As used herein,food quality starches are starches that are edible by animals, includinghuman beings.

Particularly useful hydroxypropylated distarch phosphates include thosehaving a degree of substitution in the range of from about 3.5% to about8.8%, preferably from about 5.7% to about 6.7% by weight of the boundpropylene oxide on starch. Those distarch phosphates further have adegree of crosslinking from about 0.001% to about 0.04%, preferably from0.01% to about 0.025% by weight of phosphorus oxychloride reagent usedto crosslink the starch. Weight percents are by weight of the starch.

Flours that are particularly useful for preparing the instant roux ofthe present invention include, without limitation, wheat, tapioca, rye,oat, buckwheat and soybean flour, particularly wheat flour. Particularlyuseful wheat flours have less than 16% protein content, and especiallyuseful wheat flours have less than 10% protein content.

In at least one embodiment, the process for obtaining the instant rouxcomposition of the present invention includes the step of mixing orblending a modified starch with flour. In one embodiment, the blends arecomposed of modified starch to flour over a range of weight percentratios of from about 72:28 to 93:7 starch to flour. In anotherembodiment, the blends include starches that are modified by bothcrosslinking and stabilizing and wheat flour in ratios of between about80:20 to about 90:10 modified starch to flour.

With the materials mixed, the blend is then co-processed. Co-processinginvolves subjecting the blend to a spray-cooking or drum-drying process,thereby pregelatinizing the starch. An example of a useful spray-cookingprocess is the Steam Injection Dual Atomization (“SIDA”) processdisclosed in U.S. Pat. Nos. 4,600,472 and 4,280,851. Another usefulexample is the spray-cooking process known as the “EK Process” disclosedin U.S. Pat. Nos. 5,131,953, 5,188,674, 5,281,432, 5,318,635, 5,435,851and 5,571,552. The EK Process is a continuous coupled process in whichstarch slurry is jet-cooked, then conveyed at high temperature to aspray drier and spray dried.

In the SIDA process, a mixture of the granular starch is cooked orgelatinized in an atomized state. The starch which is to be cooked isinjected as a starch slurry through an atomization aperture in thenozzle assembly into the spray of atomized steam so as to heat thestarch to a temperature effective to gelatinize the starch. An enclosedchamber surrounds the atomization and heating medium injection aperturesand defines a vent aperture positioned to enable the heated spray ofstarch to exit the chamber. The arrangement is such that the lapsed timebetween passage of the spray of starch through the chamber, i.e., fromthe atomization chamber and through the vent aperture, defines thegelatinization time of the starch. The resulting spray-driedpregelatinized starch comprises uniformly gelatinized starch in the formof indented spheres, with a majority of the granules being whole andunbroken and which swell upon rehydration. Nozzles suitable for use inthe preparation of these starches are described in U.S. Pat. No.4,610,760.

The steam injection/dual atomization process as referred to above may bemore particularly described as pregelatinization of the starch by:

-   -   a) mixing the starch in an aqueous solvent,    -   b) atomizing the mixture with an enclosed chamber, and    -   c) interjecting a heating medium into the atomized mixture in        the enclosed chamber to cook the starch, the size and shape of        the chamber being effective to maintain the temperature and        moisture control of the starch for a period of time sufficient        to cook said starch. According to the present invention, the        starch slurry can include the flour.

A steam injection/single atomization process for cooking andspray-drying starch is disclosed in the U.S. Pat. No. 5,149,799 patentreferred to above and comprises:

-   -   a) slurrying the starch in an aqueous medium,    -   b) feeding a stream of the starch slurry at a pressure from        about 50 to about 250 psig into an atomizing chamber within a        spray nozzle,    -   c) injecting a heating medium into the atomizing chamber at a        pressure from about 50 to about 250 psig,    -   d) simultaneously cooking and atomizing the starch slurry as the        heating medium forces the starch through a vent at the bottom of        the chamber, and    -   e) drying the atomized starch.

It is further noted that blends of the selected cross-linked starchesmay be used. Flour can also be slurried with the starch(es).

In those aspects where appropriate, small-scale modifications of theSIDA process may be used. One skilled in the art would recognize andknow such modifications, an example of which is illustrated infra.

According to the SIDA process, the blend is initially mixed in anaqueous solvent (e.g., a slurry is formed) at the desired solids leveland ratio of modified starch to flour. Typically, the desired solidslevel is between about 25% and about 43% by weight. In anotherembodiment, the solids level is between about 30 and about 35% byweight. The aqueous mixture is then atomized into an enclosed chamberforming a relatively fine spray that may be uniformly cooked orgelatinized. A heating medium can be interjected into the chamber tocook the material. Atomization of the slurry can be effectuated in amulti-fluid nozzle through which the slurry is conveyed, with steam (inthis embodiment, the heating medium) interjected through the nozzle intothe atomized material. This atomization process results ingelatinization of the blend.

After gelatinizing the atomized starch and flour material, thegelatinized mixture can be optionally transferred to a spray tower anddried from about 3% to about 12% moisture content by weight of the driedmixture.

After being subjected to the spray-cooking or drum-drying process, theprocessed material may optionally be agglomerated. Agglomeration may beachieved by methods known in the art, including, for instance, via batchor continuous processing. A particularly useful method of agglomerationinvolves spraying the material recovered from the spray tower with wateruntil the individual particles adhere to one another. The particles arethen dried with heated air to final moisture content of from about 3% toabout 12%.

In one embodiment, the fat component of the instant roux is co-processedwith the starch/flour blend. For example, when the SIDA process is used,the starch/flour blend can be atomized through one nozzle while the fatcomponent is atomized through another nozzle. In this manner, the liquidfat droplets are mixed with the gelatinized starch/flour blend droplets.

In another embodiment, the fat component can be sprayed with theprocessed starch/flour blend during agglomeration. In this manner, thefat component can be used to adhere the co-processed starch/flour blendparticles together.

The instant roux compositions of the present invention demonstrate acombination of desirable appearance and taste of conventional roux(i.e., roux prepared by cooking together equal portions of flour andbutter), as well as process tolerance, emulsification, cold and hottemperature stability, and instant viscosity properties.

Foods in which the instant roux of the present invention are usefulinclude, without limitation, sauces, gravies, gumbos, etoufees, andinstant type food products such as instant soups.

The following examples are presented to further illustrate and explainthe present invention and should not be taken as limiting in any regard.All parts and percentages are given by weight and all temperatures indegrees Celsius (° C.) unless otherwise noted.

EXAMPLES Example 1

Process for Preparing Co-Processed Thickening Compositions

A modified starch was prepared by stabilizing with propylene oxide to adegree of from about 5.7% to about 6.7% based on dry weight % starch,and crosslinking with phosphorus oxychloride from about 0.01% to about0.025% based on dry weight % starch. The base starch used was waxymaize. This process of modification resulted in a hydroxypropylateddistarch phosphate. This modified starch (28.3 kg) was mixed withcommercially available wheat flour (5.0 kg) and sufficient water in abatch tank so that dilatancy does not occur. The resultant slurry wasuniformly mixed with a Lightnin® Classic Mixer (Rochester, N.Y.).

This starch/flour mixture was then subjected to a small-scale modifiedsteam injection dual atomization (“SIDA”) spray-cooking process. Spraycooking was effected by a ¼ J-system comprising an air-atomizing nozzlein combination with air and fluid caps. The uniform slurry was pumped at140 psi into the air cap and gelatinized via steam at 135 psi. Thisresultant steam-pressurized and gelatinized mixture was then atomizedthrough orifices in the cap. The liquid particles were dried as theydropped through the spray tower (associated with the ¼ J-system) in airat a temperature of 236° C. and recovered as a pregelatinized drypowder. The moisture content of these dry powders was from about 3% toabout 12% by weight of the co-processed thickening composition.

The dried mixture was then agglomerated by fluidizing it in a fluidizedbed at a temperature of 90° C. while spraying water onto the driedmixture until the individual particles adhered to one another and aloose bulk density of 0.18 to 0.35 grams/cc was achieved.

Process for Preparing Non-Instant Roux Using the Co-Processed ThickeningComposition

Non-instant roux were prepared by blending the above co-processedthickening composition with a variety of stearins or fats in variousratios to determine the preferred combination. The blends were comparedagainst a real roux, i.e., an equal blend of butter and flour, a dilutedreal roux containing 17% solids, a commercially available white saucemix containing 11% solids (available from Knorr, a division of UnileverBestfoods, Englewood Cliffs, N.J.), and a commercially available browngravy mix containing 11% solids (available from Knorr, a division ofUnilever Bestfoods, Englewood Cliffs, N.J.).

Examples 1a-1d

The following tables 1a-1d illustrate the various fats tested and theratio of fat to thickening composition used— TABLE 1a Butter as fatIngredient Amount of Ingredient (%) Butter 12.5 26.3 41.6 Thickener of87.5 73.7 58.3 Example 1

The butter was melted and added to the thickener. Each butter/thickenerblend provides a good roux with good smell. However, because the processrequires the step of melting the butter and adding that melted butter tothe thickener, it is not considered an instant or ready-to-use roux forpurpose of the present invention. TABLE 1b Partially Hydrogenated palmoil as fat Ingredient Amount of Ingredient (%) Palm Oil 12.5 26.3 41.6Thickener of 87.5 73.7 58.3 Example 1

This blended product becomes grainy, especially after cooling. Theproduct is also grainy if it is not cooked enough. TABLE 1c Driedvegetable oil as fat (Dritex ®, available from HUMKO Oil Products,Cordova, TN) Ingredient Amount of Ingredient (%) Vegetable Oil 12.5 26.341.6 Thickener of 87.5 73.7 58.3 Example 1

This particular fat did not blend with the thickener, i.e., noemulsification. The fat separated on top of the thickener. TABLE 1dPowdered vegetable shortening containing hydrogenated soybean oil andmilk protein (sodium caseinate) (Beatreme) as fat Ingredient Amount ofIngredient (%) Beatreme 12.5 26.3 41.6 Thickener 87.5 73.7 58.3This blend produced the most opaque product with best taste.

Example 2

Fat-Free Instant Roux

A fat-free powder blend instant roux was prepared as follows. A blend of44.4% flour (commercially available wheat flour), 30% co-processedthickening composition according to Example 1, and 25.6% maltodextrin(pregelatinized tapioca maltodextrin, available as Instant Oil II,National Starch and Chemical Company, Bridgewater, N.J.) was prepared.The blend was added to heated water to produce a roux. The fat-free rouxhad good color, but had a powdery taste.

Example 3

Instant Roux with Emulsifier

A variety of instant roux powders were prepared using several differentemulsifiers. The product composition and results are provided in thefollowing Tables 3a-3c. TABLE 3a Modified Starch as emulsifierIngredient Amount (%) Flour 18.2 Thickener of 29.7 Example 1 Fat(stearin) 42.5 Modified starch 9.6

The starch used was modified waxy maize, available as N-Creamer™ 46 fromNational Starch and Chemical Company, Bridgewater, N.J. The fat was notstable in the blend, resulting in poor emulsifying properties and agrainy texture. TABLE 3b Soy lecithin as emulsifier Ingredient Amount(%) Flour 18.2 Thickener of 36.4 Example 1 Fat (stearin) 21.2 Soylecithin 6

This instant roux product provided good emulsification with a goodproduct. TABLE 3c Whey protein as emulsifier Ingredient Amount (%) Flour18.2 Thickener 36.4 Fat (stearin) 21.2 Whey protein 6This instant roux product provided good emulsification with a goodproduct.

Example 4

All dry mixes were compared to both the gold standard, i.e., real roux(50% butter and 50% flour), and the white Knorr roux mentioned inExample 1 supra (hydrogenated oil and flour). The mixes were evaluatedfor the following characteristics:

-   -   Easiness of dispersion in hot water (lumps or no lumps)    -   Speed of hydration (short, long) to reach full viscosity    -   Stability on a hot table over time (0, 2, 6 hours) with        Brookfield viscosity measurement with a Brookfield    -   Stability after refrigeration at 4° C. (after 3 days) with        syneresis or not

Using a ratio of 30% fat to 70% thickener of Example 1, with viscosityadjusted to be equal in each, the following results were determined—TABLE 4a Comparison of Hydration and Dispersion Speed of Easiness ofCooking Hydration dispersion Real roux Long easy Thickener of short Abit stirring Example 1 + Stearine required as fat Thickener of short Abit stirring Example 1 + Beatreme required 2784 Thickener of short A bitstirring Example 1 + Centenial 1 required Knorr roux Long easy

Hydration to reach equal viscosity was never fully reached with the realroux and Knorr product (flour-containing bases). It is reached duringthe holding on a steam table (see below). The thickener of Example 1 ishydrating in the mixes nearly instantaneously—it only needs to be heldfor 45 seconds at 90° C. to reach full viscosity. In one aspect, theinstant roux compositions should be stirred initially to avoid too rapidhydration and formation of lumps. TABLE 4b Steam Table Stability Steamtable stability T = 0 T = 2 hours T = 6 hours Real roux 8150 12060 6000Thickener of Example 8000 8120 8310 1 + Stearine Thickener of Example1 + Beatreme 7950 8100 8070 2784 Thickener of Example 1 + 7890 8010 7990Centenial 1 Knorr roux 8430 10400 7050Average of 3 viscosity measurements (cP) on a Brookfield, 15 sec,spindle 04, rpm 10, at 70° C.

The real roux and Knorr mix first increase in viscosity (as the flour isyet not fully cooked) and then breakdown over time. In contrast, theinstant roux compositions of the present invention do not break downover time. The instant roux reached full viscosity at t=0 and remainedstable overtime. TABLE 4c Effect on Syneresis Refrigeration SyneresisReal roux ++ Thickener of Example 0 1 + Stearine Thickener of Example 0(smoother) 1 + Beatreme 2784 Thickener of Example 0 (smoother) 1 +Centenial 1 Knorr roux ++Retrogradation of the amylose contained in the flours produces visiblesyneresis. In contrast, the instant roux did not retrograde. The instantroux with emulsifier provides a product that is more opaque andsmoother, with both phases (fat and oil) holding together better thanthe real roux and Knorr mix.

Various powdered caramel colors were added to a blend of 87.5% of thethickener of Example 1 and 12.5% fat. A range of colors were createdthat mimic various degrees of cooking of a real roux. Titanium dioxideswas also added to improve opacity.

Various types of commercially available powdered flavors were added to ablend of 87.5% of the thickener of Example 1 and 12.5% fat. Theseincluded, e.g., Butter Buds® (from Butter Buds Food Ingredients, Racine,Wis.), and Edlong® lipolytic butter flavor, cooked butter flavor andtoasted butter flavor (from Edlong® Flavors, Elk Grove Village, Ill.). Arange of flavors were created.

1. A ready-to-use roux composition comprising a processed thickener andfat.
 2. The roux composition of claim 1 wherein the processed thickenerfurther comprises starch and flour.
 3. The roux composition of claim 2wherein the starch is a modified starch.
 4. The roux composition ofclaim 3 wherein the modified starch is a crosslinked starch.
 5. The rouxcomposition of claim 3 wherein the modified starch is a thermallyinhibited starch.
 6. The roux composition of claim 2 wherein the starchis a stabilized starch.
 7. The roux composition of claim 6 wherein thestabilized starch is a hydroxyalkylated distarch phosphate or anacetylated distarch adipate.
 8. The roux composition of claim 2 whereinthe flour is wheat flour having a protein content of less than about16%.
 9. The roux composition of claim 8 wherein the flour is wheat flourhaving a protein content of less than about 10%.
 10. The rouxcomposition of claim 2 wherein the starch and the flour are present in aratio of from about 72:28 to about 93:7 by weight, respectively.
 11. Theroux composition of claim 10 wherein the starch and the flour arepresent in a ratio of from 80:20 to about 90:10 by weight, respectively.12. The roux composition according to claim 3 wherein the modifiedstarch is a dihydroxypropylated distarch phosphate waxy maize starchsubstituted to a degree of from about 5.7% to about 6.7% by weight ofpropylene oxide reagent used to stabilize the starch.
 13. The rouxcomposition according to claim 12 wherein the modified starch is acrosslinked starch substituted from about 0.01% to about 0.025% byweight of phosphorus oxychloride reagent used to crosslink the starch.14. The roux composition according to claim 2 wherein the flour is wheatflour having 10% protein content, and the starch and the flour arepresent in a ratio of 85:15 wt % starch to flour.
 15. The rouxcomposition according to claim 14 wherein the starch and flour areco-processed via the SIDA process.
 16. A food product comprising theroux composition of claim
 1. 17. The food product of claim 16 whereinthe food is selected from the group consisting of sauces, gravies,gumbos, etoufees, and instant food products.
 18. A process for preparinga ready-to-use roux composition for use in foods comprising the stepsof: creating a slurry of starch and flour, coprocessing the starch/flourslurry so as to gelatinize at least part of the starch, drying thegelatinized starch/flour blend to form a coprocessed thickener, andblending the coprocessed thickener with a fat.
 19. The process accordingto claim 18 wherein the starch and flour are co-processed via the SIDAprocess.
 20. The process according to claim 18 further comprisingblending the coprocessed thickener and fat with flour.
 21. The processaccording to claim 18 further comprising blending the coprocessedthickener and fat with at least one emulsifier.
 22. The processaccording to claim 18 further comprising blending the coprocessedthickener and fat with at least one dye.
 23. The process according toclaim 18 further comprising blending the coprocessed thickener and fatwith at least one flavor.